Festool Sander for use with Styrofoam

[LaserGecko]

Yet another question...

What sander would be best for use with styrofoam? I'm going to be doing quite a bit of hot wire foam work (eventually). It makes an incredible mess that's not easy to clean since the dust weighs practically nothing.

Perfect job for a Festool, eh?

If anyone has experience with this, please share! It's been a long while since I've done it, so I don't remember what kind of sanders we used.

Thanks,
Jason

 

[mysterium]

Jason,

I'm not sure about "which sander"... 'cause about any sander with an aggressive abrasive will cut styrofoam fast......

But if you don't have a CT vacuum, you might want to consider one because of it's anti static hose.  My experience on cutting styrofoam is that the "dust/shavings" goes everywhere... It also sticks everywhere because of the static electricity it creates being machined.  And I for one don't like the shocks... 

jim

 

[LaserGecko]

Hi Jim,

Thanks for the reply. I figured that a CT was going to be in the shop by the time I get to that point. The dust extraction on these things actually makes me want to do it again.

Which one do you think would be most comfortable to use in that situation?

Jason

 

[John Langevin]

What sort of projects are you building? Are you going to use the sander as the primary shaping tool? How fine are the styrofoam granules? My only experience with styrofoam was in insulating my barn to build my shop. I was using 2 5/8" thick 4'x8' "Laboratory Refrigeration Grade"  sheets that I found along I-91 20 years ago. I needed to cut each piece in width to fit since the "carpenters" who built my barn didn't grasp the concept of 24" on center. The cuts obviously weren't that critical so in lieu of my (then) ATF55 and guide rail I used my PS300 D-handle pendulum saw (freehand to a marked line) with my CT-22E extractor. Obviously this isn't ideal since the collection efficiency of the saw is probably the least of any other tool. However after cutting 22 sheets I probably had a 10 ounce cup full of loose debris; needless to say I was quite impressed.

 

[Ned]

The Wave knife blade for the jigsaw works well on styrofoam.  Very little debris, since it's cleaving rather than chipping.  Maybe using this blade will reduce the need for sanding.

I've also made neat narrow rolls of paper towels and aluminum foil.  Having the jigsaw table-mounted helps here, I think.  If you do it freehand, your experience may vary.

Like Vlies if you have a Rotex, IMO everyone with a jigsaw should have some Wave blades.  You will find a use for them, and be glad you had them on hand.

Ned

 

[mysterium]

Ned,

Thanks for bringing my attention to the wave knife blade.  I missed that one, foam rubber is a pain to cut.

jim

 

[John Langevin]

Ditto to Ned, I wasn't aware of the Wave Blade. When I need one I will thank you again.